Basalt fiber toughened composite resin-based photovoltaic support material and preparation method thereof

Abstract

The invention belongs to the technical field of photovoltaic materials, and particularly relates to a basalt fiber toughened composite resin-based photovoltaic support material and a preparation method thereof. The photovoltaic support material is composed of 20-35% of flame-retardant resin and 55-80% of basalt fiber, and the total mass percentage content is 100%. Wherein the flame-retardant resin is prepared from the following components in parts by mass: 70 to 120 parts of matrix resin, 0.05 to 0.2 part of an accelerant, 0.01 to 0.1 part of a polymerization inhibitor and 10 to 20 parts of a flame retardant. Under the condition of meeting the same wind load, snow load, self-weight load and earthquake load, the weight of the prepared basalt fiber toughened composite resin-based photovoltaic support material is about 49.5% of the weight of a steel photovoltaic support, the weight can be greatly reduced, and the transportation and installation cost is reduced.

Description

Technical Field

[0001] The invention belongs to the technical field of photovoltaic materials, and specifically relates to a basalt fiber toughened composite resin-based photovoltaic bracket material and a preparation method thereof. Background Art

[0002] Due to different lighting conditions and topography, different regions have different requirements for photovoltaic brackets. For example, the photovoltaic brackets required in the northwest region are required to be wind-resistant, while the photovoltaic brackets in the south are required to have better corrosion resistance. At present, the photovoltaic brackets on the market are mainly hot-dip galvanized steel brackets, and aluminum alloy brackets, weathering steel brackets and other materials account for a relatively small proportion. Hot-dip galvanized photovoltaic brackets are formed by cold bending of ordinary steel, and then sent to the hot-dip galvanizing plant for pickling and hot-dip galvanizing. The processing efficiency is high, but the coating is prone to defects, the delivery cycle is long, and the environmental pollution is large. Aluminum alloy photovoltaic brackets are brackets made of extruded aluminum alloy materials. The surface is generally anodized. They are light in weight, beautiful in appearance, and have extremely high corrosion resistance, but the cost is high. They are generally used in household rooftop power stations with load-bearing requirements and strong corrosion environments.

[0003] The ore raw material of basalt fiber is volcanic rock. It is an environmentally friendly, pure natural green fiber with the advantages of wide sources, relatively low price, and balanced performance. It is a fiber with high strength, excellent modulus performance, high temperature resistance, easy to manufacture, cheap, non-toxic, natural, and environmentally friendly. However, the surface of basalt fiber is chemically inert and has poor wettability with the matrix resin, which makes it impossible for basalt fiber to fully exert its mechanical properties, thereby affecting the performance of the composite material. Therefore, although there are records of basalt fiber being used in photovoltaic brackets on the market, its preparation method is complicated and the amount of basalt fiber added is low. If the preparation method is inappropriate or the amount added is high, the flame retardant grade may be low, and the tensile strength, impact toughness, etc. may not meet the requirements. Therefore, we still need to further develop it in order to better use basalt fiber in the photovoltaic industry. Summary of the invention

[0004] The purpose of the present invention is to provide a basalt fiber toughened composite resin-based photovoltaic bracket material and a preparation method thereof to address the problems existing in the prior art (such as photovoltaic bracket products are prone to rust, are not flame retardant, and have poor mechanical properties). The basalt fiber toughened composite resin-based photovoltaic bracket material is scientifically formulated and adopts a one-time molding process. The cross-section of the mold can be designed to be various profiles such as circular, rectangular, C-shaped, and L-shaped. The prepared bracket material has a series of excellent properties such as high strength, high temperature resistance, corrosion resistance, aging resistance, low thermal conductivity, low moisture absorption rate, and high volume resistivity.

[0005] In order to achieve the above invention objectives, the specific technical solutions adopted in this application are:

[0006] One of the purposes of the present invention is to protect a basalt fiber toughened composite resin-based photovoltaic bracket material, wherein the photovoltaic bracket material is composed of 20-35% (specifically 20%, 22%, 24%, 26%, 28%, 30%, 32%, 34%, 35%, etc.) flame retardant resin, 55-80% (specifically 55%, 60%, 65%, 70%, 75%, 80%, etc.) basalt fiber, and the total mass percentage is 100%;

[0007] The flame retardant resin comprises, by weight, 70 to 120 parts of base resin (specifically 70, 75, 80, 85, 90, 95, 100, 105, 110, 115, 120, etc.), 0.05 to 0.2 parts of accelerator (specifically 0.05, 0.1, 0.15, 0.2, etc.), 0.01 to 0.1 parts of polymerization inhibitor (specifically 0.01, 0.02, 0.03, 0.04, 0.06, 0.07, 0.08, 0.10, 0.11, 0.12, 0.13, 0.14, 0.16, 0.17, 0.18, 0.19, 0.20, 0.21, 0.23, 0.24, 0.25, 0.26, 0.27, 0.28, 0.29, 0.30, 0.31, 0.32, 0.33, 0.34, 0.35, 0.36, 0.37, 0.38, 0.39, 0.40, 0.41, 0.42, 0.43, 0.44, 0.45, 0.46, 0.47, 0.48, 0.49, 0.50, 0.51, 0.52, 0.53, 0.54, 0.56, 0.57, 0.58, 0.59, 0.60, 0.61, 0.62, 0.64, 0.65, 0.66, 0.67, 0.68 0.02 parts, 0.03 parts, 0.04 parts, 0.05 parts, 0.06 parts, 0.07 parts, 0.08 parts, 0.09 parts, 0.1 parts, etc.), 10 to 30 parts of flame retardant (specifically 10 parts, 11 parts, 12 parts, 13 parts, 14 parts, 15 parts, 16 parts, 17 parts, 18 parts, 19 parts, 20 parts, 21 parts, 21 parts, 22 parts, 23 parts, 24 parts, 25 parts, 26 parts, 27 parts, 28 parts, 29 parts, 30 parts, etc.).

[0008] Furthermore, in the matrix resin of the basalt fiber toughened composite resin-based photovoltaic bracket material, the following are included by weight: 180 to 210 parts of diol (specifically 180 parts, 185 parts, 190 parts, 195 parts, 200 parts, 205 parts, 210 parts, etc.), 80 to 100 parts of unsaturated acid anhydride (specifically 80 parts, 85 parts, 90 parts, 95 parts, 100 parts, etc.), 140 to 250 parts of saturated dibasic acid or acid anhydride; 160 parts (specifically 140 parts, 145 parts, 150 parts, 155 parts, 160 parts, etc.), 190-220 parts of styrene (specifically 190 parts, 195 parts, 200 parts, 205 parts, 210 parts, 215 parts, 220 parts, etc.), 20-30 parts of additives (specifically 20 parts, 21 parts, 22 parts, 23 parts, 24 parts, 25 parts, 26 parts, 27 parts, 28 parts, 29 parts, 30 parts, etc.).

[0009] Furthermore, in the basalt fiber toughened composite resin-based photovoltaic support material, the accelerator includes one or more of toluene diisocyanate, toluene, 3-dimethylaminopropylamine, triethylenediamine or DC-829.

[0010] Furthermore, in the basalt fiber toughened composite resin-based photovoltaic support material, the polymerization inhibitor includes one or more of hydroquinone, 2,6-di-tert-butyl-p-cresol, p-tert-butylcatechol or p-hydroxyanisole.

[0011] Furthermore, in the basalt fiber toughened composite resin-based photovoltaic support material, the flame retardant includes one or more of ammonium polyphosphate, phosphate ester, phosphonate ester, phosphine oxide or melamine.

[0012] Furthermore, in the basalt fiber toughened composite resin-based photovoltaic support material, the diol includes one or more of ethylene glycol, propylene glycol, pentanediol, and dipropylene glycol; the unsaturated acid anhydride includes one or more of maleic anhydride and fumaric anhydride.

[0013] More preferably, ethylene glycol is selected as the diol, because the influence of ethylene glycol on the application materials is mainly reflected in the following aspects:

[0014] 1. Improve flexibility and impact resistance: Ethylene glycol is a weak polar solvent with good compatibility with most resins. Adding ethylene glycol can improve the flexibility of the resin, reduce the hardness and brittleness of the resin, and thus improve the toughness and impact resistance of the resin;

[0015] 2. Reduce viscosity: An appropriate amount of ethylene glycol can reduce the viscosity of the resin, making the resin coating easier to apply, improving production efficiency and reducing construction difficulty;

[0016] 3. Improve film-forming properties: The addition of ethylene glycol can evaporate slowly, increase the drying time, and make the resin flow and form better during the coating, spraying and other processes, thereby improving the film-forming properties;

[0017] 4. Delay drying time: When using resin coatings in low temperature environments, ethylene glycol can adjust the drying time to prevent the coating from drying too quickly or unevenly;

[0018] 5. Prevent bubbling: Ethylene glycol can reduce the surface tension of the coating, reduce the occurrence of bubbling and improve the coating quality.

[0019] Furthermore, in the basalt fiber toughened composite resin-based photovoltaic bracket material, the saturated dibasic acid or anhydride includes one or more of phthalic acid, isophthalic acid, terephthalic acid, and phthalic anhydride; the auxiliary agent includes one or more of hydroquinone, p-tert-butylcatechol, ethylenediamine, and diphenylamine.

[0020] The present invention also protects a method for preparing the above-mentioned basalt fiber toughened composite resin-based photovoltaic bracket material, which comprises the following steps:

[0021] The matrix resin, accelerator, inhibitor and flame retardant are heated respectively and then evenly mixed to obtain a flame retardant resin liquid; then the basalt fiber is immersed in the flame retardant resin liquid and heated again to cross-link and cure, thereby obtaining a basalt fiber toughened composite resin-based photovoltaic bracket material.

[0022] Preferably, in the preparation method of the basalt fiber toughened composite resin-based photovoltaic bracket material, the heating temperature is 45-75°C (specifically, it can be 45°C, 50°C, 55°C, 60°C, 65°C, 70°C, 75°C, etc.).

[0023] The basalt fiber toughened composite resin-based photovoltaic bracket material described above or the basalt fiber toughened composite resin-based photovoltaic bracket material obtained by the method has the following characteristics:

[0024] (i) Tensile strength 329-372 MPa, tensile modulus 25.1-28.2 GPa;

[0025] (ii) Longitudinal bending strength 306-331 MPa, transverse bending strength 119-151 MPa;

[0026] (iii) Under ultraviolet irradiation for 3000 h, the tensile strength retention rate is 93-100%, and the compressive strength retention rate is 95-100%;

[0027] (iv) When propane is ignited for 30 seconds and then removed, the flame goes out naturally in 1.11 seconds. When propane is ignited for 60 seconds and then removed, the flame goes out naturally in 2.57 seconds. The flame retardancy level reaches B1.

[0028] The present invention also protects a photovoltaic bracket, which is prepared by using the basalt fiber toughened composite resin-based photovoltaic bracket material.

[0029] As a preferred embodiment of the method for preparing the basalt fiber toughened composite resin-based photovoltaic bracket material of the present invention, wherein:

[0030] Basalt fiber composite photovoltaic bracket is made by pultrusion process, which refers to a continuous process of using fiber reinforcement material and resin matrix to produce a constant cross-sectional profile.

[0031] In the production process of basalt fiber-reinforced composite resin-based photovoltaic bracket materials, pigments or other conventional raw materials can also be added according to conventional techniques; during preparation, basalt reinforcing fibers, matrix resins, pigments and other raw materials are passed through a heated mold to convert them into FRP composite products.

[0032] Furthermore, the cross-section can be designed into various profiles such as circular, rectangular, C-shaped, L-shaped, etc. through the mold. It has a series of excellent properties such as high strength, high temperature resistance, corrosion resistance, aging resistance, low thermal conductivity, low moisture absorption rate, and high volume resistivity.

[0033] The preparation of basalt fiber composite photovoltaic bracket, the specific steps are as follows:

[0034] Step 1: Feed the raw materials into the guide rail

[0035] Basalt fiber is drawn out from the yarn tube on the creel and arranged in a neat and uniform manner to obtain basalt fiber roving. In this process, it is necessary to ensure that each bundle of basalt fiber is accurately placed in the predetermined position to ensure the performance of the final product.

[0036] The continuous basalt fiber roving is fed into the machine guide through the execution guide, in which the basalt fiber roving usually passes through a tensioner to obtain preformed basalt fiber;

[0037] Step 2: Soak the fiber in the resin solution

[0038] The preformed basalt fiber is passed through an impregnation tank for resin infusion. The impregnation tank contains a flame retardant resin, pigments, and a catalyst to aid curing. The forming rail is placed before, during, or after the resin tank.

[0039] Step 3: Enter heating / curing

[0040] The resin-impregnated basalt reinforcement fibers are passed through a heated die.

[0041] When the impregnated reinforcement is exposed to the heated mold, the cross-linking process begins and it gradually solidifies.

[0042] The cross-linking process is exothermic, and the resin temperature can even exceed the mold temperature during the entire process. This usually happens at the end of the heating process, causing the resin to naturally detach from the mold. Therefore, it is very important to maintain the optimal temperature throughout the infiltration process. If the temperature is too high, cracks will appear in the composite material. In addition, if the temperature is not high enough, the resin will not be fully cross-linked. High or low temperatures will result in composite profiles that do not meet quality requirements in terms of strength and stiffness.

[0043] Step 4: Separation

[0044] Separation begins at the end of the mold heating process, using a reciprocating hydraulic clamp puller for pulling.

[0045] After separation, the cured profiles are cut to the required length using an automatic saw

[0046] The third object of the present invention is to overcome the deficiencies in the prior art and provide a photovoltaic bracket.

[0047] In order to solve the above technical problems, the present invention provides the following technical solutions: comprising:

[0048] A load-bearing assembly, comprising a plurality of oblique beams, and a plurality of purlins fixed to the plurality of oblique beams;

[0049] A support assembly including a front column and a rear column connected to the diagonal beam;

[0050] Wherein, the preparation material of the load-bearing component and the supporting component is basalt fiber toughened composite resin-based material.

[0051] Compared with the prior art, this application has the following beneficial effects:

[0052] (1) Lightweight: Basalt fiber-reinforced composite resin-based photovoltaic bracket materials are lightweight and high-strength. Compared with traditional metal materials, they are lighter, which can reduce the weight of photovoltaic brackets and reduce transportation and installation costs.

[0053] (2) Corrosion resistance: Basalt fiber-reinforced composite resin-based photovoltaic bracket material has good corrosion resistance and can be used for a long time in harsh environments. It is not easily affected by oxidation and corrosion, thus extending the service life of the photovoltaic bracket.

[0054] (3) Wind pressure resistance: Basalt fiber-reinforced composite resin-based photovoltaic bracket materials have high strength and stiffness, which can effectively resist wind pressure and vibration, ensuring the stability and safety of the photovoltaic bracket.

[0055] (4) Good insulation performance: Basalt fiber toughened composite resin-based photovoltaic bracket material has good insulation performance, which can effectively prevent the occurrence of electrical accidents and improve the safety of photovoltaic systems.

[0056] (5) Easy processing: Basalt fiber toughened composite resin-based photovoltaic bracket materials can be processed through molding, extrusion and other processes, and can be customized according to different needs to improve the adaptability and flexibility of photovoltaic brackets.

[0057] (6) Under the same conditions of wind load, snow load, deadweight load and earthquake load, the weight of the basalt fiber toughened composite resin-based photovoltaic bracket material prepared by the present invention is about 49.5% of the weight of the steel photovoltaic bracket, which can greatly reduce the weight and reduce the transportation and installation costs.

[0058] (7) The strength of the basalt fiber toughened composite resin-based photovoltaic bracket material prepared by the present invention is about 4 times that of ordinary steel, and has a higher elastic modulus, which can meet the strength and stiffness requirements of the photovoltaic bracket.

[0059] (8) Under 3000 h of ultraviolet irradiation, the strength and modulus of the basalt fiber-reinforced composite resin-based photovoltaic bracket material have a high retention rate, which can meet the outdoor durability requirements and reduce the subsequent maintenance costs of the bracket. BRIEF DESCRIPTION OF THE DRAWINGS

[0060] Figure 1 Impact performance of basalt fiber toughened composite resin based photovoltaic bracket materials.

[0061] Figure 2 This is a schematic diagram of the structure of a photovoltaic bracket. DETAILED DESCRIPTION

[0062] In order to make the above-mentioned objects, features and advantages of the present invention more obvious and easy to understand, the specific implementation methods of the present invention are described in detail below in conjunction with the embodiments of the specification.

[0063] In the following description, many specific details are set forth to facilitate a full understanding of the present invention, but the present invention may also be implemented in other ways different from those described herein, and those skilled in the art may make similar generalizations without violating the connotation of the present invention. Therefore, the present invention is not limited to the specific embodiments disclosed below.

[0064] Secondly, the term "one embodiment" or "embodiment" as used herein refers to a specific feature, structure, or characteristic that may be included in at least one implementation of the present invention. The term "in one embodiment" that appears in different places in this specification does not necessarily refer to the same embodiment, nor does it refer to a separate or selective embodiment that is mutually exclusive with other embodiments.

[0065] The raw materials used in the present invention are all commercially available unless otherwise specified.

[0066] The abbreviations of the substances are as follows:

[0067] Toluene diisocyanate (TDI), p-tert-butylcatechol (TBC), ammonium polyphosphate (APP)

[0068] The performance of the material prepared in the embodiment of the present invention was tested as follows:

[0069] The longitudinal tensile strength, longitudinal tensile elastic modulus, longitudinal bending strength and transverse bending strength were measured according to GB / T 31539-2015 and GB / T 1449-2005.

[0070] Refer to GB / T31539-2015, GB / T2573-2008, GB / T3857-2017, GB / T16422.3-2014 to measure water resistance, alkali resistance, and ultraviolet aging performance. Water resistance test conditions: medium deionized water, temperature (80±2)℃, cycle 7 days; alkali resistance test conditions: medium saturated calcium hydroxide solution, temperature (23+2)℃, cycle 7 days; ultraviolet aging performance exposure conditions: 8h drying, 4h condensation, cycle 15 days. Measure the longitudinal tensile strength and longitudinal compressive strength respectively and calculate their corresponding strength retention rates.

[0071] Measure the combustion performance with reference to GB / T20284 and GB / T 8626. Ignite the burner in the vertical direction and wait for the flame to stabilize. Adjust the fine-tuning valve of the burner and use a suitable tool that can display a flame height of 20 mm with a fixed point on the burner as the measurement starting point to measure the flame height. The flame height should be 20 mm. This operation should be performed at a preset position away from the burner to avoid accidental ignition of the sample. The flame height should be measured before igniting the sample each time. Record the time it takes for the flame to naturally go out after the commercial propane burner is removed after igniting the sample for 30s and 60s.

[0072] This embodiment provides a basalt fiber toughened composite resin-based photovoltaic bracket material, and the specific preparation method is as follows:

[0073] 195 parts (parts by weight, each part can be regarded as 1 kg or 1 g, etc., the same below) of ethylene glycol, 90 parts of maleic anhydride, 150 parts of phthalic acid, 205 parts of styrene, and 25 parts of hydroquinone are mixed evenly to obtain a base resin.

[0074] Take 95 parts of base resin, 0.125 parts of toluene diisocyanate, 0.05 parts of hydroquinone, and 15 parts of ammonium polyphosphate, heat and mix them evenly to obtain a flame retardant resin liquid.

[0075] Calculated by mass percentage, 80% of basalt fibers were immersed in 20% flame retardant resin liquid, and cross-linked and cured at 60° C. to obtain a basalt fiber toughened composite resin-based photovoltaic bracket material.

[0076] Example 2

[0077] The difference between this embodiment and embodiment 1 is that the matrix resin formula is adjusted to take 160 parts (by weight) of ethylene glycol, 90 parts of maleic anhydride, 150 parts of phthalic acid, 205 parts of styrene, and 25 parts of hydroquinone and mix them evenly. The rest of the preparation process is the same as that of embodiment 1 to obtain a basalt fiber toughened composite resin-based photovoltaic bracket material.

[0078] Example 3

[0079] The difference between this embodiment and embodiment 1 is that the matrix resin formula is adjusted to take 245 parts (by weight) of ethylene glycol, 90 parts of maleic anhydride, 150 parts of phthalic acid, 205 parts of styrene, and 25 parts of hydroquinone and mix them evenly. The rest of the preparation process is the same as that of embodiment 1 to obtain a basalt fiber toughened composite resin-based photovoltaic bracket material.

[0080] The performance of the materials prepared in the above examples was tested, and the specific results are shown in Table 1.

[0081] Table 1

[0082]

[0083] As can be seen from the above table, the influence of adjusting the ethylene glycol ratio in the matrix resin formula on the performance of the composite material is significant. If the number of ethylene glycol parts is too high, the viscosity of the resin will be reduced, so that the interface bonding force of the composite material is reduced, and the overall strength and rigidity of the composite material will be affected. In addition, if the ethylene glycol fraction is too low, the viscosity of the resin will increase, the difficulty of the product molding process will increase, and the toughness and impact resistance of the composite material will be reduced, affecting the overall strength and rigidity of the composite material product. The ethylene glycol content in the matrix resin is high or low, and the result will cause the composite material profile strength, rigidity, water resistance, alkali resistance and ultraviolet aging performance to decrease. According to the results in the above table, the best technical effect can be obtained when the matrix resin ethylene glycol in the present invention is taken at 195 parts.

[0084] Example 4

[0085] The difference between this embodiment and embodiment 1 is that the curing temperature is adjusted to 45° C., and the rest of the preparation process is the same as that of embodiment 1, to obtain a basalt fiber toughened composite resin-based photovoltaic bracket material.

[0086] Example 5

[0087] The difference between this embodiment and embodiment 1 is that the curing temperature is adjusted to 75° C., and the rest of the preparation process is the same as that of embodiment 1, to obtain a basalt fiber toughened composite resin-based photovoltaic bracket material.

[0088] The performance tests were performed on the materials prepared in the above examples, and the specific results are shown in Table 2.

[0089] Table 2

[0090]

[0091] As can be seen from the above table, adjusting the curing temperature has a significant impact on the performance of the composite material. If the temperature is too high, cracks will appear in the composite material. In addition, if the temperature is not high enough, the resin will not be completely cross-linked. High or low temperatures will result in reduced strength, stiffness, water resistance, alkali resistance and ultraviolet aging performance of the composite material profile. According to the results in the above table, the best technical effect can be obtained when the curing temperature in the present invention is 60°C.

[0092] Example 6

[0093] The difference between this embodiment and embodiment 1 is that the content of basalt fiber is adjusted to 55%, and the rest of the preparation process is the same as that of embodiment 1, so as to obtain a basalt fiber toughened composite resin-based photovoltaic bracket material.

[0094] Example 7

[0095] The difference between this embodiment and embodiment 1 is that the content of basalt fiber is adjusted to 80%, and the rest of the preparation process is the same as that of embodiment 1 to obtain a basalt fiber toughened composite resin-based photovoltaic bracket material. The performance of the material obtained in the above embodiment is tested, and the comparison results with those of embodiment 1 are shown in Table 3.

[0096] Table 3

[0097]

[0098] Depend on Figure 1 As can be seen from Table 3, the impact energy absorption and maximum impact force of basalt fiber composite materials with different fiber contents are compared: within a certain range, the higher the fiber content, the higher the strength and stiffness of the composite material; the lower the fiber content, the better the toughness and impact resistance of the composite material. However, when the fiber content is too high, the connection between the fibers is very tight, which makes it difficult to diffuse the stress, and the toughness and impact resistance of the material will decrease. Therefore, the present invention selects 70% basalt fiber content as the best according to the specific application scenario and design requirements.

[0099] Example 8

[0100] The difference between this embodiment and embodiment 1 is that the proportion of flame retardant in the flame retardant resin formula is adjusted to 45%, and the rest of the preparation process is the same as that of embodiment 1 to obtain a basalt fiber toughened composite resin-based photovoltaic bracket material.

[0101] Example 9

[0102] The difference between this embodiment and embodiment 1 is that the proportion of flame retardant in the flame retardant resin formula is adjusted to 12%, and the rest of the preparation process is the same as that of embodiment 1 to obtain a basalt fiber toughened composite resin-based photovoltaic bracket material.

[0103] The performance of the materials prepared in the above examples was tested, and the specific results are shown in Table 4.

[0104] Table 4

[0105]

[0106] It can be seen from the above table that adjusting the flame retardant component ratio has a significant impact on the performance of the composite material. If the flame retardant component is too high, the strength of the composite material decreases, and the average strength is only 50% of that in Example 1. In addition, if the flame retardant component is not high enough, the flame retardant grade does not meet the standard requirements. Whether the flame retardant component ratio is high or low, the result will lead to a decrease in the strength, stiffness, water resistance, alkali resistance, ultraviolet aging performance, and flame retardant performance of the composite material profile. According to the results in the above table, the best technical effect can be obtained when the flame retardant component in the present invention accounts for 21.27%.

[0107] Comparative Example 1

[0108] The steel materials of commercially available photovoltaic brackets are generally Q235 and 345.

[0109] Comparative Example 2

[0110] The aluminum alloy photovoltaic brackets available on the market are generally made of 2021A aluminum alloy.

[0111] The density of the basalt fiber toughened composite resin-based photovoltaic bracket material in Example 1 of the present application is 2.0 g / cm 3 ;

[0112] The density of steel is 7.8g / cm 3 ;

[0113] The density of aluminum alloy is 2.7g / cm 3 ;

[0114] By comparison, it can be seen that the photovoltaic bracket in this application can be used to compare with the photovoltaic bracket with steel structure or aluminum alloy structure to reduce weight by 40%-60%, and the cost can be reduced by about 10%, with significant advantages in weight reduction and cost reduction.

[0115] Maintenance-free: no corrosion or rust, removable and disassembled, convenient for later maintenance

[0116] Good material properties: good corrosion resistance and fatigue performance

[0117] Application examples:

[0118] This embodiment provides an example of a photovoltaic bracket using Tianjin as an example.

[0119] According to GB 50797-2012 "Design Specifications for Photovoltaic Power Stations", the design service life of the photovoltaic bracket is set at 25 years, the safety level is level three, and the structural importance coefficient is not less than 0.95; the seismic category of the photovoltaic bracket structure is Class D.

[0120] According to the "Building Structure Load Code" and the geological, meteorological and hydrological data of Tianjin, the wind pressure load is calculated to be 0.5kN / m 2 ; Snow pressure load is 0.4kN / m 2 Based on HYPERWORK finite element analysis software, the strength, stiffness and stability of the structure are calculated to determine the basic structural form of the photovoltaic bracket.

[0121] A single photovoltaic array is composed of 8 structural units consisting of 48 solar panels, 16 purlins, 8 diagonal beams, 8 diagonal braces, 8 rear columns, and 8 front columns, forming an array structure with a total length of 27958mm. Each structural unit is composed of a support, a front column, a rear column, a diagonal brace, a diagonal beam, and connectors of each component. One end of the front and rear columns is set on the support through a connector, and the other end is connected to the two ends of the diagonal beam through a connector. The middle of the diagonal beam is connected to the rear column through a diagonal brace. The photovoltaic support column and foundation, the column and the diagonal beam are rigidly connected, and the support beam and the diagonal beam are hinged.

[0122] The photovoltaic array includes solar photovoltaic panels and photovoltaic brackets, among which the photovoltaic bracket is an array structure composed of bars, diagonal beams, front and rear columns, diagonal braces and connectors. After optimization, a single set of photovoltaic brackets contains 16 bars, 10 diagonal beams, 10 diagonal braces, 10 front columns, 10 rear columns and corresponding connectors and standard parts. Figure 2 shown.

[0123] ① The purlins, diagonal beams, columns and diagonal braces are all made of basalt fiber toughened composite resin-based photovoltaic bracket materials. After the pultrusion molding process is optimized, the basic shape and size are as follows:

[0124] The purlin has an overall dimension of 45mm×65mm, with a T-shaped slot and reinforcing ribs in the middle for fixing the photovoltaic panel blocks, a basic thickness of 5mm, and a transverse reinforcing rib and bottom thickness of 4mm;

[0125] The inclined beams and columns are rectangular square tubes with an outer dimension of 40mm×50mm, with a wall thickness of 4mm on the upper and lower surfaces and 5mm on the two side walls;

[0126] The diagonal brace is a rectangular square tube with an outer dimension of 40mm×40mm and a wall thickness of 4mm.

[0127] ②The connector is made of carbon steel (Q235) and is designed as a "U"-shaped connector to limit the axial and radial displacement of the purlins and pillars. The thickness of 4mm can meet the bending strength requirements, and a bolt connection hole is added at the end to improve the connection stability.

[0128] ③The density of the concrete material used to fix the anchor bracket is 2500kg / m 3 , Young's modulus is 30 GPa, and Poisson's ratio is 0.2.

[0129] According to the three-dimensional data of the photovoltaic bracket, the overall symmetrical modeling is adopted to establish the finite element model; the pre-processing software uses the ANSA software, and the solver uses the ABAQUS software; the composite materials are all modeled using the Solid composite material modeling method, the C3D8 unit is discretized, and the concrete is simulated by the solid C3D8 unit; the bolt connection is simplified to MPC, and the interaction at the key position is simulated by Contact Pair.

[0130] According to the load calculation requirements, the force acting on a single photovoltaic panel is calculated as shown in Table 5 below.

[0131] Table 5 Photovoltaic panel forces

[0132] Load Force acting on a single photovoltaic panel Force acting on a single photovoltaic panel at a single installation point direction Permanent load 266.6N 66.6N Vertical Wind Load 1831N 457.8N Photovoltaic panel normal Snow load 340N 85.0N Vertical

[0133] Load Combinations

[0134] When calculating the deformation and displacement of structures and components according to the normal use limit state and the strength of structures and components according to the bearing capacity limit state, the load adopts a basic combination, which mainly has two types: permanent load + wind load, permanent load + snow load. According to the calculated variable load value, it can be known that the wind load is much larger than the snow load, and only the combined working condition of wind load can be considered when combining working conditions.

[0135] Table 6 Load combination conditions

[0136]

[0137] As described above, according to the provisions of GB50797-2012 “Design Specifications for Photovoltaic Power Stations” and simulation verification, the photovoltaic support structure provided by the present invention meets the performance requirements.

[0138] It should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention rather than to limit it. Although the present invention has been described in detail with reference to the preferred embodiments, those skilled in the art should understand that the technical solutions of the present invention may be modified or replaced by equivalents without departing from the spirit and scope of the technical solutions of the present invention, which should all be included in the scope of the claims of the present invention.

Claims

1. A basalt fiber toughened composite resin-based photovoltaic support material, characterized in that: The photovoltaic support material is composed of 20-35% flame retardant resin and 55-80% basalt fiber, with a total mass percentage of 100%; The flame retardant resin comprises, by weight, 70 to 120 parts of base resin, 0.05 to 0.2 parts of accelerator, 0.01 to 0.1 parts of inhibitor, and 10 to 20 parts of flame retardant.

2. The basalt fiber toughened composite resin-based photovoltaic bracket material according to claim 1, characterized in that: The base resin includes, by weight, 180 to 210 parts of diol, 80 to 100 parts of unsaturated acid anhydride, 140 to 160 parts of saturated dibasic acid or acid anhydride, 190 to 220 parts of styrene, and 20 to 30 parts of auxiliary agent.

3. The basalt fiber toughened composite resin-based photovoltaic bracket material according to claim 1, characterized in that: The accelerator includes one or more of toluene diisocyanate, toluene, 3-dimethylaminopropylamine, triethylenediamine or DC-829; the inhibitor includes one or more of hydroquinone, 2,6-di-tert-butyl-p-cresol, p-tert-butylcatechol or p-hydroxyanisole; the flame retardant includes one or more of ammonium polyphosphate, phosphate ester, phosphonate ester, phosphine oxide or melamine.

4. The basalt fiber toughened composite resin-based photovoltaic bracket material according to claim 2, characterized in that: The diol includes one or more of ethylene glycol, propylene glycol, pentanediol, and dipropylene glycol; the unsaturated acid anhydride includes one or more of maleic anhydride and fumaric anhydride.

5. The basalt fiber toughened composite resin-based photovoltaic bracket material according to claim 2, characterized in that: The saturated dibasic acid or anhydride includes one or more of phthalic acid, isophthalic acid, terephthalic acid, and phthalic anhydride; the auxiliary agent includes one or more of hydroquinone, p-tert-butylcatechol, ethylenediamine, and diphenylamine.

6. The method for preparing the basalt fiber toughened composite resin-based photovoltaic support material according to any one of claims 1 to 5, characterized in that The following steps are involved: The matrix resin, accelerator, inhibitor and flame retardant are heated respectively and then evenly mixed to obtain a flame retardant resin liquid; then the basalt fiber is immersed in the flame retardant resin liquid and heated again to cross-link and cure, thereby obtaining a basalt fiber toughened composite resin-based photovoltaic bracket material.

7. The method for preparing the basalt fiber toughened composite resin-based photovoltaic bracket material according to claim 6, characterized in that: The heating temperature is 45-75°C.

8. The basalt fiber toughened composite resin-based photovoltaic support material according to any one of claims 1 to 5, characterized in that: The material has the following characteristics: (i) Tensile strength 329-372 MPa, tensile modulus 25.1-28.2 GPa; (ii) Longitudinal bending strength 306-331 MPa, transverse bending strength 119-151 MPa; (iii) Under ultraviolet irradiation for 3000 h, the tensile strength retention rate is 93-100%, and the compressive strength retention rate is 95-100%; (iv) When propane is ignited for 30 seconds and then removed, the flame goes out naturally in 1.11 seconds. When propane is ignited for 60 seconds and then removed, the flame goes out naturally in 2.57 seconds. The flame retardancy level reaches B1.

9. A photovoltaic support, characterized in that The basalt fiber toughened composite resin-based photovoltaic bracket material as described in any one of claims 1 to 5 is used.

10. The photovoltaic support according to claim 9, characterized in that: It includes a load-bearing component and a supporting component; the load-bearing component includes an inclined beam and a purlin fixed to the inclined beam; the supporting component includes a front column and a rear column connected to the inclined beam; the load-bearing component and the supporting component are both prepared by using a basalt fiber toughened composite resin-based material.

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